KR20200142598A - Continuous casting of materials using pressure differential - Google Patents

Abstract

Systems and methods for continuous casting. The system includes a melting chamber, a recovery chamber and a secondary chamber between them. The melting chamber can maintain the melting pressure and the recovery chamber can reach atmospheric pressure. The secondary chamber may include regions that can be adjusted to different pressures. During a continuous casting operation, the first region adjacent to the melting chamber may be adjusted to a pressure at least slightly greater than the melting pressure; The pressure in successive areas can be continuously decreased and then increased continuously. The subforce of the final area can be at least slightly greater than atmospheric pressure. The differential pressures can form a dynamic airlock between the melting chamber and the recovery chamber to prevent inert gas in the atmosphere from penetrating into the melting chamber and thus prevent contamination of reactive materials inside the melting chamber.

Description

Continuous casting of materials using pressure difference{CONTINUOUS CASTING OF MATERIALS USING PRESSURE DIFFERENTIAL}

This disclosure relates generally to systems, methods, tools, techniques and strategies for casting molten material. In some embodiments, the disclosure relates to continuous casting of molten material.

For example, a furnace such as a plasma arc or electron beam cold hearth furnace can melt and cast material over a period of time. During the continuous casting operation, the molten material continuously enters the mold and the casting material or ingot can continuously flow out of the mold. For example, molten material can be introduced into the top of the mold and a withdrawal mechanism is continuously translated to allow casting material to flow out of the bottom of the mold. Continuous casting can reduce the frequency of interruptions in the casting operation, for example delays associated with the replacement of the mold between casting cycles. Reduction of interruptions during the casting operation can increase casting efficiency.

Some materials are reactive when they are molten or at high temperatures. When in a molten state, heated to a certain temperature, or heated above a certain temperature, such a reactive material may or may not chemically bond easily when exposed to certain elements or compounds, and will readily change chemically. For example, titanium melted at very high temperatures and solid cast titanium chemically readily combine with gaseous oxygen to form titanium oxide and gaseous nitrogen to form titanium nitride. Titanium oxide and titanium nitride can form hard alpha defects in cast titanium and make them unsuitable for desired applications. As a result, the molten titanium and hot cast titanium are kept in a vacuum or inert atmosphere at certain stages of the casting operation. A high vacuum or virtual vacuum is maintained in the melting and casting chamber in the electron beam cold hearth furnace to enable the operation of the electron beam guns. Plasma torches in plasma arc cold hearth furnaces use an inert gas, for example helium or argon, to generate plasma. Thus, the presence of an inert gas for the plasma torch in a plasma arc cold hearth furnace creates a pressure inside the furnace that can range from negative pressure to positive pressure. When a non-inert gas such as oxygen or nitrogen, for example, permeates the melting chamber of a plasma arc or electron beam cold hearth furnace, the non-inert gas may contaminate the molten material therein. Therefore, it is necessary to completely or substantially block gas from the outside atmosphere from entering the melting chamber of the furnace containing molten titanium.

It would be advantageous to provide a continuous casting system that is less susceptible to contamination of titanium or other reactive materials contained within the continuous casting system. More generally, it would be advantageous to provide an improved continuous casting system generally useful for titanium, other reactive materials and metals and metal alloys.

Summary of the invention

One aspect of this disclosure relates to a non-limiting embodiment of a system for melting and casting materials. The system includes a melting chamber, a secondary chamber, and a recovery chamber. The melting chamber is configured to operably reach a melting pressure therein. Further, the secondary chamber includes a plurality of regions and at least one pressure regulating element. The plurality of regions includes a first region positioned adjacent the melting chamber, the first region being configured to operably reach a first differential pressure greater than the melting pressure therein. Each pressure regulating element controls the flow of gas between adjacent regions of the plurality of regions. Further, the recovery chamber is located adjacent to the secondary chamber, and the recovery chamber is configured to operably reach atmospheric pressure therein.

The secondary chamber may include an inner perimeter, and each pressure regulating element may include a baffle and a central aperture for receiving through the cast material. The baffle of each pressure adjusting element may extend from the inner periphery to the central hole. The melting chamber may contain a mold for casting the material. The cast material can pass from the mold into the recovery chamber through a central hole of the at least one pressure regulating element of the secondary chamber. The plurality of regions may include a second region adjacent to the first region, and the second region may be configured to operably reach a second differential pressure less than the first differential pressure. The system may include a plurality of pumps configured to regulate pressure within a plurality of regions of the secondary chamber. The system includes a recovery cart configured to move the recovery chamber away from the secondary chamber, the recovery chamber being configured to reach atmospheric pressure when moving away from the secondary chamber. The system may include rollers configured to operably extend towards the cast material recovered from the secondary chamber.

Another aspect of the disclosure relates to a non-limiting embodiment of a method for casting a material. The method includes controlling the pressure inside the melting chamber, the secondary chamber, and the recovery chamber. The pressure inside the melting chamber is controlled by the melting pressure. The method also includes passing cast material from the melting chamber into the secondary chamber, the secondary chamber comprising a plurality of regions, the plurality of regions comprising a first region adjacent to the melting chamber. do. The method also includes passing the material from the secondary chamber into a recovery chamber. The method also includes controlling the pressure in the first region from a melt pressure to a first differential pressure greater than the melt pressure. The method also includes controlling the pressure in the recovery chamber from the melt pressure to atmospheric pressure.

The method includes controlling a pressure in a second region of the secondary chamber to a second differential pressure less than the first differential pressure, the second region being located adjacent to the first region. The method includes controlling the pressure in the final region of the secondary chamber to a final differential pressure greater than atmospheric pressure, the final region being operably located adjacent to the recovery chamber. The method includes controlling the pressure in regions located between the second region and the intermediate region of the secondary chamber, the pressures being adjusted from the melting pressure to a pressure that continuously decreases from the second region to the intermediate region. . The method includes controlling a pressure in regions between the intermediate region and the final region, the pressures being adjusted from a melt pressure to a pressure continuously increasing from the intermediate region to the final region. The method includes applying energy to a material within a melting chamber to melt the material. The method may include passing the cast material through the secondary chamber into the recovery chamber using a recovery mechanism. The method may include deconstraining the recovery chamber from the secondary chamber to control the pressure in the recovery chamber from melt pressure to atmospheric pressure. The method may include extending a set of rollers to contact the cast material. The method may include cutting the cast material with a cutting device. The method may include unloading the cut segments of the cast material onto a loading cart.

Another aspect of the present disclosure relates to a non-limiting embodiment of a chamber for a continuous casting furnace. The chamber includes an inner periphery, a plurality of regions, and at least one baffle for controlling gas flow between adjacent regions of the plurality of regions. The plurality of regions includes a first region located adjacent to the melting chamber of the furnace, the melting chamber is configured to operably reach a melting pressure, the first region at a first differential pressure greater than the melting pressure. It is configured to be operatively reached. The plurality of regions also includes a second region located adjacent to the first region, the second region being configured to operably reach a second differential pressure less than the first differential pressure. Each baffle includes an aperture, and each baffle extends from the inner periphery of the chamber to the aperture.

Features and advantages of the present invention may be better understood with reference to the accompanying drawings.
1 schematically depicts a continuous casting system according to at least one non-limiting embodiment of the present disclosure;
Fig. 2 is a partial schematic illustration of the continuous casting system of Fig. 1 showing molten material inside the melting chamber;
FIG. 3 is a partial schematic view of the continuous casting system of FIG. 1 showing a recovery ram withdrawing cast material through a secondary chamber;
Figure 4 is a detailed illustration of the continuous casting system of Figure 3 showing the baffles of the secondary chamber;
FIG. 5 is a partial schematic view of the continuous casting system of FIG. 1 showing a recovery ram for withdrawing cast material into a recovery chamber;
6 is a detailed illustration of the continuous casting system of FIG. 5 showing the differential pressure regions of the secondary chamber;
Figure 7 is a partially schematic view of the continuous casting system of Figure 1 showing first rollers extending towards the cast material and a recovery chamber released from the secondary chamber;
Fig. 8 is a schematic view of the continuous casting system of Fig. 1 showing a recovery cart and a recovery chamber separated from the furnace and a unloading apparatus for unloading the cut segments of the cast material;
Fig. 9 schematically shows the continuous casting system of Fig. 8 showing the unloading device for removing cut segments of cast material;
FIG. 10 is a schematic illustration of the continuous casting system of FIG. 1 showing a recovery chamber and a recovery cart removed from the furnace and an optional unloading device for unloading the cast material;
11 is a flow schematic diagram illustrating a process for the continuous casting system of FIG. 1 in accordance with at least one non-limiting embodiment of the present disclosure.

The various non-limiting embodiments described and disclosed herein relate to continuous casting systems for metals and metal alloys. In some non-limiting embodiments, the metal or metal alloys are reactive materials. A non-limiting embodiment described and illustrated herein is a secondary chamber between the recovery chamber and the melting chamber of a melting and casting system, which melting chamber is suitable for plasma arc or electron beam cold hearth melting. However, it will be appreciated that the secondary chamber can be used with any melting chamber, such as for example melting chambers suitable for coreless induction and/or channel-shaped induction melting.

In various non-limiting embodiments, the continuous casting system may include a melting chamber, a recovery chamber, and a secondary chamber arranged between the melting chamber and the recovery chamber. In some embodiments, the melting chamber may include an energy source capable of energizing and melting the material located therein. The molten material can move into the mold of the casting melting chamber. When the material is properly solidified, the material can be separated from the mold and withdrawn through the secondary chamber into the recovery chamber. All material or areas of material may still be molten or partially molten until removed from the mold. Initially, the desired melting pressure can be obtained through the melting chamber, the secondary chamber and the recovery chamber. The desired melting pressure may be, for example, a vacuum, an intermediate pressure less than atmospheric pressure, or a positive pressure higher than atmospheric pressure. If the desired melting pressure is a positive pressure, gas can be introduced into the continuous casting system. An inert gas may be used within the chambers and/or regions of a continuous casting system in which the material may react with the inert gas. For example, an inert gas may be used in the melting chamber to melt and cast a material such as titanium that is reactive when melted. In at least one embodiment, the melting chamber can be maintained at a desired melting pressure during a continuous casting operation. Also, in some embodiments, the gas in the recovery chamber may be adjusted to atmospheric pressure. For example, the recovery chamber may be unconstrained from the secondary chamber to provide space for lengthening cast material or cast material to exit the continuous casting system. When the recovery chamber moves away from the second chamber, the recovery chamber may have atmospheric pressure.

In various non-limiting embodiments, the pressure inside the secondary chamber can be adjusted or controlled during a continuous casting operation. For example, the secondary chamber may include a plurality of regions. Further, the pressure regulating element and the casting material arranged through holes in the pressure regulating element can control the flow of gas between adjacent ones of the plurality of areas. In other words, adjacent regions within the secondary chamber can be adjusted and maintained at different pressures. In various non-limiting embodiments, the first region adjacent to the melting chamber may be adjusted to a pressure at least slightly higher than the desired melting pressure. In at least one embodiment, the regions between the first region and the intermediate region of the secondary chamber may be adjusted to a continuous and incrementally decreasing pressure. In some embodiments, the first region of the secondary chamber adjacent to the recovery chamber may be adjusted to a pressure slightly higher than atmospheric pressure. In at least one embodiment, the regions between the intermediate region and the final region can be adjusted with a continuous and incrementally increasing pressure. In other words, the first region may be the first high pressure region, the middle region may be a relatively low pressure region, and the final region may be the second high pressure region.

In various non-limiting embodiments, the secondary chamber may form a dynamic airlock between the recovery chamber and the melting chamber. For example, a higher pressure in the first region and a pressure decreasing from the first region to the continuous region of the secondary chamber will guide or direct the gas away from the first region and the recovery chamber toward the continuous region of the secondary chamber. I can. Directing the gas away from the melting chamber can avoid contamination of the reactive material inside the melting chamber. Further, it may be prevented from flowing from the external atmosphere to the final region at a position adjacent to the recovery chamber and/or the final region of the secondary chamber by a relatively high pressure in the final region of the secondary chamber. By limiting the penetration of atmospheric gas into the secondary chamber, contamination of the reactive material in the melting chamber can be further prevented.

1-10, a non-limiting embodiment of a continuous casting system 20 may include a furnace 22 for molten and/or cast material. In various non-limiting embodiments, the furnace 22 may include a plasma arc cold hearth furnace or an electron beam cold hearth furnace. In an alternative embodiment, another suitable furnace may be used to melt the material within the continuous casting system 20. In some embodiments, the continuous casting system 20 may include a melting chamber 30, a secondary chamber 50 and/or a recovery chamber 80. The furnace 22 can, for example, melt the material 24 arranged in the melting chamber 30. In at least one embodiment, the secondary chamber 50 may be located close to the melting chamber 30, and the recovery chamber 80 may be located close to the secondary chamber 50. For example, the secondary chamber 50 may be arranged between the melting chamber 30 and the recovery chamber 80.

When referring mainly to FIG. 1, the melting chamber 30, the secondary chamber 50, and the recovery chamber 80 may be sealed together or be sealed to be released from restraint. For example, the melting chamber 30 may be sealed with the secondary chamber 50, and the secondary chamber 50 may be sealed with the recovery chamber 80. In various non-limiting embodiments the seal between the melting chamber 30, the secondary chamber 50 and/or the recovery chamber 80 may be broken during a casting operation. As described herein, for example, the recovery chamber 80 may be arranged movably relative to the secondary chamber 50, so that the recovery chamber 80 can move away from the secondary chamber 50 and It is possible to break the seal between (Fig. 7). In various non-limiting embodiments, the melting chamber 30, the secondary chamber 50 and the recovery chamber 80 are capable of forming and/or maintaining a uniform or substantially uniform pressure. For example, the melting chamber 30, the secondary chamber 50, and the recovery chamber 80 may be sealed to each other and controlled to a desired melting pressure. In various non-limiting embodiments, at least two of the chambers 30, 50, and 80 may be controlled with different pressures. For example, the pressure inside the melting chamber 30, the secondary chamber 50, and the recovery chamber 80 is a dynamic airlock that prevents the penetration of non-inert gas into the melting chamber 30 of the furnace 22. It can be adjusted during continuous casting operation to provide airlock. For example, the desired melting pressure may be a positive pressure. Initially, the melting chamber 30, the secondary chamber 50, and the recovery chamber 80 may be controlled to a positive desired melting pressure. In various non-limiting embodiments, the pressure may be uniform or substantially uniform across the chambers 30,50,80 such that only a minor pressure or nominal pressure change is within the chambers 30,50,80. exist. Subsequently, the recovery chamber 80 may be opened to an external atmosphere, thereby forming an atmospheric pressure, and the melting chamber 30 may maintain a desired melting pressure therein. In the above embodiments, the pressure across the secondary chamber 50 is that an external atmosphere positioned within the recovery chamber 80 and/or outside the secondary chamber 50 penetrates into the melting chamber 30. It can be adjusted to create a dynamic airlock that prevents it.

Still referring to FIG. 1, the continuous casting system 20 may include a pumping system that controls the pressure in the melting chamber 30, the secondary chamber 50 and/or the recovery chamber 80. The pumping system forms, for example, the melting chamber 30, the secondary chamber 50 and the recovery chamber 80 with a vacuum and/or, for example, the pressure inside the chambers 30,50,80 Can be adjusted to various static pressures. In various non-limiting embodiments, the pumping system may control the melting chamber 30, the secondary chamber 50, and the recovery chamber 80 at the same pressure. Additionally or alternatively, the pumping system may control at least two of the chambers 30, 50, and 80 at different pressures. Thus, the pumping system may include multiple pumps, gas sources and/or gas bleeds to regulate the pressure inside the chambers 30, 50, 80. For example, the melting chamber 30 may include a melting chamber pumping system, the secondary chamber 50 may include a secondary chamber pumping system, and the recovery chamber 80 may include a recovery chamber pumping system. Can include. Each pumping system may comprise a gas source and a bleed, ie, for example, a backfill system. Further, the secondary chamber pumping system may include differential pressure pumps 60. As described herein, the differential pressure pump 60 may control pressure in various regions 62 of the secondary chamber 50, for example. Also, as described herein, the pumping system forms a closed loop or a partially closed loop system, so that at least a portion of the gas inside the continuous casting system 20 is recovered, purified and recycled through the continuous casting system 20. Can be.

Referring first to FIG. 2, the melting chamber 30 of the continuous casting system 20 may contain a material 24 therein for melting and casting. The energy or heat source 32 of the furnace 22 may extend into the melting chamber 30 and supply energy to the material located therein. For example, the energy source 32 may generate a high intensity electron beam or plasma arc across the surface of the material 24. In various non-limiting embodiments the melting chamber 30 may comprise a vessel or hearth 34 such as, for example, a water-cooled copper hearth. Still referring to FIG. 2, when the heat source 32 applies energy to the material 24 located in the hearth 34 to melt the material 24, the hearth 34 (24) can be fixed.

In various non-limiting embodiments, the melting chamber 30 may include a crucible or mold 36. Molten material 24 may, for example, enter the mold 36 and leave the mold 36 as, for example, cast material 26. Referring now to Fig. 3, the mold 36 is a mold with an open substructure, so that the cast material 26 can leave the lower part of the mold 36 during a continuous casting operation. Further, the mold 36 may have an inner perimeter that matches the desired shape of the cast material 26. The inner circumference of a circle may, for example, form a cylinder and the inner circumference of a rectangle may form, for example, a rectangular prism. In various non-limiting embodiments, the mold 36 may have a circular inner perimeter having a diameter of, for example, from about 6 inches to about 32 inches. Further, in various non-limiting embodiments, the mold 36 may have a rectangular inner perimeter, for example, about 36 inches versus about 54 inches. In various non-limiting embodiments the mold 36 may be a water-cooled copper mold. In some embodiments, the mold 36 may form a portion of the outer periphery of the melting chamber 30 and may be sealed to the melting chamber 30 and/or the secondary chamber 50. For example, the mold 36 may form a sealed passage between the melting chamber 30 and the secondary chamber 50.

Mainly referring to FIGS. 2 and 3, a dovetail plate 40 may be inserted into the mold 36 to form a lower surface movable therein. The dovetail plate 40 can be separated or removed from the mold 36 and pulled through the melting furnace 22 during a continuous casting operation, for example. In at least one embodiment, the dovetail plate 40 may be a water-cooled copper plate. In various non-limiting embodiments the dovetail plate 40 can be connected to a recovery element 42 that can be connected with a withdrawal ram 82. The recovery ram 82 may include an extension and retraction mechanism such as a hydraulic cylinder or a ball screw assembly, for example. In various non-limiting embodiments, the recovery ram 82 can pull the recovery element 42 and the attached dovetail plate 40 into the recovery chamber 80 through the secondary chamber 50. have. In at least one embodiment, a starter block 44 may be inserted into the dovetail plate 40, and a restraint pin 46 attaches the starter block 44 to the dovetail plate 40. It can be fixed so that it can be released. In various non-limiting embodiments, the starter block 44 is the dovetail plate 40 from the mold 36, as described in U.S. Patent No. 6,273,179 to Mr. Geitzer et al., which is incorporated herein by reference in its entirety. ) And the cast material 26 can be easily removed, and the end of the cast material 26 can be continuously and easily separated from the dovetail plate 40.

Referring again to FIG. 2, the energy source 32 may provide energy to the material 24 located inside the hearth 34 to melt the material 24. In various non-limiting embodiments, the material 24 can flow from the hearth 34 into the mold 36. In at least one embodiment, the hearth 34 may be tilted or tilted to inject the molten material 24 into the mold 36. In other embodiments the molten material 24 may overflow from the hearth into the mold 36. Still referring to FIG. 2, the molten material 24 can flow into the mold 36 having an open bottom. In various non-limiting embodiments, when the molten material 24 flows into the mold 36, the molten material 24 is, for example, the dovetail plate 40 and/or the starter. Block 44 can be covered and, for example, can be in contact with the sides of the mold 36.

In various non-limiting embodiments, the molten material 24 is, for example, titanium (Ti), zirconium (Zr), magnesium (Mg), vanadium (V), niobium (Nb) and/or a specific temperature. It may contain materials such as alloys of the same materials that can react with gases present in the atmosphere. For example, titanium can react at elevated temperatures and molten states. In order to protect the reactive material during the melting and casting process, the atmosphere inside the melting chamber 30 and other areas of the continuous casting system 20 where the material is substantially hot and thus reactive can be controlled. For example, the pressure inside the melting chamber 30 may be substantially formed in a vacuum state and/or the melting chamber 30 may be filled with an inert gas. When the furnace 22 is an electron beam cold hearth melting furnace, the pressure of the melting chamber 30 may be, for example, approximately vacuum, and when the furnace 22 is a plasma arc cold hearth melting furnace, the melting chamber 30 is For example, it may be backfilled with an inert gas to a sub-atmospheric pressure or a positive pressure higher than atmospheric pressure.

2 and 3 again, the molten material 24 filling the mold 36 may form a molten seal 28 between the melting chamber 30 and the secondary chamber 50. have. In various non-limiting embodiments the molten material 24 may be positioned adjacent to the sidewalls of a portion of the mold 36. For example, still referring to FIGS. 2 and 3, the molten material 24 may be adjacent to the inner periphery of the mold 36 along the top or surface of the material filling the mold 36. I can. In various non-limiting embodiments, the molten seal 28 is otherwise introduced into the melting chamber 30 from the secondary chamber 50 and/or the external atmosphere, or the molten material 24 therein. ) Can provide a barrier to limit and/or block the flow of gases that can react. In various non-limiting embodiments, the cast material 26 may solidify or substantially solidify upon leaving the mold 36. It will be understood that at least the outer circumferential regions of the cast material 26 are suitably solidified to maintain the integrity of the cast material 26 when the cast material 26 leaves the mold 36. . Mainly referring to FIG. 3, when the molten material 24 reaches a desired height in the mold 36, the dovetail plate 40 opens the mold 36 by the recovery ram 82. Can be contracted through the bottom. When the cast material 26 is attached thereto, the recovery ram 82 pulls the recovery fixture 42 and the dovetail plate 40 from the mold 36 toward the secondary chamber 50. You can pull. In various non-limiting embodiments, the rate at which the cast material 26 is recovered from the mold 34 is the rate at which the molten material 24 flows from the hearth 34 to the mold 36 In the same way, the height of the molten material 24 inside the mold 36 remains substantially the same during the continuous casting process. For example, the recovery rate of the cast material 26 may range from about 100 pounds/hour to about 2000 pounds/hour. In various non-limiting embodiments the recovery rate may be, for example, from about 1500 pounds/hour to about 5000 pounds/hour. The recovery rate may depend on the design of the furnace, for example the dimensions of the cast material 26, such as the cross-sectional area, and/or the properties of the cast and molten material 24,26, such as, for example, the density.

Mainly referring to FIGS. 4 to 6, the melting chamber 30 may be fixed to the secondary chamber 50. For example, the melting chamber 30 may be clamped, bolted, fixed or otherwise fixed to the secondary chamber 50. In at least one embodiment, for example, an O-ring or gasket may be arranged between the melting chamber 30 and the secondary chamber 50 to provide a vacuum seal sealing therebetween. In various non-limiting embodiments, the melting chamber 30 and the secondary chamber 50 are fixed to be deconstrained from each other so that the mold 36 arranged therebetween is removed, replaced and/or Can be exchanged. In various non-limiting embodiments, as described herein, the mold 36 may form a sealed passage between the melting chamber 30 and the secondary chamber 50. In addition, the secondary chamber 50 may be positioned adjacent to and/or below the melting chamber 30, for example. In various non-limiting embodiments, the secondary chamber 50 is, for example, a melting chamber 30 that can be operably controlled to a desired melting pressure and, for example, a melting chamber that can be operably controlled to atmospheric pressure. A dynamic seal or airlock may be formed between the recovery chambers 80. In some embodiments, the secondary chamber 50 may include a cooling system (not shown in the drawings). The secondary chamber 50 prevents overheating of the secondary chamber 50 by the cast material 26 by pumping water and/or other cooling liquids through the channel, including, for example, a channel. It is possible to continue cooling the cast material 26 in the secondary chamber 50.

Still referring to FIGS. 4 to 6, the secondary chamber 50 may include at least one pressure adjusting element 64 for controlling gas flow between adjacent regions 62 of the plurality of regions. have. For example, the pressure regulating element 64 can be adapted to maintain a desired pressure within each region 62 of the secondary chamber 50. In some embodiments, the secondary chamber 50 may include, for example, a series of pressure regulating elements 64. The pressure regulating element 64 may be, for example, a baffle or diaphragm described in U.S. Patent No. 3,888,3000 to Mr. Guichard et al., which is incorporated herein by reference in its entirety. In various non-limiting embodiments, the pressure regulating element 64 may extend, for example, from the inner periphery of the secondary chamber 50 toward the center of the secondary chamber 50. In at least one embodiment, the pressure regulating element 64 may comprise a hole 66 which may be located in or close to the center of the pressure regulating element 64, for example. The hole 66 may be configured to receive the cast material 26 when the cast material 26 is withdrawn through the secondary chamber 50. When the secondary chamber 50 is, for example, cylindrical in shape and the cast material 26 is, for example, cylindrical in shape, the pressure adjusting element 64 may be a circular disk with circular holes. In various non-limiting embodiments the holes 66 through the pressure regulating element 64 are adjacent to the secondary chamber 50 when the cast material 26 is positioned through the adjacent regions 62. It can be sized to limit the transition of pressure and limit gas flow between regions. In addition, roller assemblies (not shown in the drawings) support the elongated cast material 26 as described in U.S. Patent No. 3,888,3000 to Mr. Guichard et al., which is incorporated herein by reference in its entirety. It may be located between the secondary chamber 50 and/or the pressure regulating element 64 for this purpose.

Referring to FIG. 6, when the cast material 26 extends through the regions 62 of the secondary chamber 50, the pressure regulating element 64 is, for example, of the secondary chamber 50. It can extend from the inner periphery towards the cast material 26. In various non-limiting embodiments, the pressure regulating element 64(s), the inner circumference of the secondary chamber 50 and the cast material 26 are of a region 62 within the secondary chamber 50. Form boundaries. For example, in the secondary chamber 50, the third differential pressure region 62c is defined as the second pressure regulating element 64b, the third pressure regulating element 64c, the inner circumference of the secondary chamber 50 and the cast material. The boundary can be formed by (26). In various non-limiting embodiments, the region 62 may be bounded by another surface within one of the chambers 30,50,50. For example, the first differential pressure region 62a is bounded by the surface of the mold 36, the first pressure regulating element 64a, the inner surface of the secondary chamber 50 and the cast material 26. can do. In various non-limiting embodiments, the hole 66 through the pressure regulating element 64 provides sufficient space for the cast material 26 so that the pressure regulating element 64 is not in contact with the It is fitted through the pressure regulating element 64. The holes 66 can be formed, for example, only slightly larger than the cross-sectional area of the mold 36 so that the distance between the pressure regulating element 64 and the cast material 26 extending through them is minimized. do. In at least one embodiment, the distance between the cast material 26 and the pressure regulating element 64 may be, for example, from about 2 mm to about 5 mm. In other embodiments the distance between the molded material 26 and the pressure regulating element 64 may be less than about 2 mm, for example.

In various non-limiting embodiments the pressure regulating element 64 may be a metal such as stainless steel, for example. The pressure regulating elements 64 may comprise an inner channel (not shown in the drawing) and the inner channel as described in U.S. Patent No. 3,888,3000 to Mr. Guichard et al. Water and/or other cooling fluid may be pumped through the channels to cool the furnace 22. In at least one embodiment, the channels inside the pressure regulating element 64 are connected with the channels inside the chamber wall, so that water and/or other cooling liquids pass through the chamber wall and the pressure regulating element 64 extending therefrom. Can be cycled through. Referring primarily to FIG. 4 in various non-limiting embodiments, the pressure adjustment element 64 may comprise brushes 68. The brushes 68 extend from the inner circumference of the pressure adjustment element 64 toward the cast material 26 and will further reduce the spacing between the cast material 26 and the pressure adjustment element 64. I can. The brush 68 may be, for example, a metal such as stainless steel. In various non-limiting embodiments, the brushes 68 may have sufficient flexibility so that contact between the cast material 26 and the brush 68 will not damage the pressure regulating element 64. Also in various non-limiting embodiments, contact between the cast material 26 and the brushes 68 will not contaminate the cast material 26.

Referring primarily to FIGS. 5 and 6, the pressure regulating elements 64 may extend between adjacent differential pressure regions 62 within the secondary chamber 50. For example, the first pressure regulating element 64a can extend between the first differential pressure area 62a and the second differential pressure area 62b, and the second pressure regulating element 64b is It may extend between the pressure region 62b and the third differential pressure region 62b, and the third pressure adjustment element 64c is between the third differential pressure region 62c and the fourth differential pressure region 62d, It can be extended on the back. In various non-limiting embodiments, the first differential pressure region 62a may be located adjacent and/or directly below the melting chamber 30. Further, the second differential pressure region 62b may be positioned adjacent to and/or directly below the first differential pressure region 62a, for example. In various non-limiting embodiments, the final or terminal differential pressure region 62g may be located adjacent and/or directly above the recovery chamber 80. Further, in at least one embodiment, the intermediate differential pressure region 62d may be located between the second differential pressure region 62b and the final differential pressure region 62g, for example. In certain non-limiting embodiments, at least one additional differential pressure region 62c is located and/or at least one additional, for example, in the second differential pressure region 62b and the intermediate differential pressure region 62d. The differential pressure regions 62e and 62f may be positioned between the intermediate differential pressure region 62d and the final differential pressure region 62g, for example.

Still referring to Figures 5 and 6, the secondary chamber 50 is, for example, seven differential pressure zones 62a, 62b, 62c, 62d, 62e, 62f, 62g and, for example, seven pressures. It may include adjustment elements 64a, 64b, 64c, 64d, 64e, 64f, 64g. The number of zones 62 and corresponding pressure regulating elements 64 within the secondary chamber 50 is at least, for example, between the properties of the melted and cast material 24 and 26 and/or the desired melt pressure and atmospheric pressure. Can depend on the pressure difference of

In various non-limiting embodiments, primarily referring to FIG. 5, the differential pressure pumps 60 are capable of regulating the pressure within each differential pressure region 62 of the secondary chamber 50. For example, differential pressure pumps 60 may extract gas from the regions 62. In at least one embodiment the differential pressure pump 60 can operatively vacuum or substantially vacuum the region 62. In addition, gas sources 52 and 54 and the corresponding gas bleeds 56 and 58 pump gas into the region 62 to increase the pressure therein. In various non-limiting embodiments, a plurality of first gas bleeds 56a, 56b, 56c, 56d extend from the first gas source 52 and a plurality of second gas bleeds 58a, 58b, 58c, 58d. ) May extend from the second gas supply source 54. The gas bleeds 56 and 58 may introduce, for example, about 1 SCFM to about 25 SCFM of gas into each region 62. The first gas source 52 may, for example, hold a first gas or a first gas combination, and the second gas source 54 may, for example, hold a second gas or a second gas combination. I can. As described herein, in various non-limiting embodiments at least one gas source 52, 54 may hold, for example, an inert gas or a combination of inert gases. In various non-limiting embodiments, the gas sources 52,54 can distribute the gas into multiple gas bleeds 56,58. In addition, the differential pressure pump 60, the gas supply sources 52, 54, and the gas bleeds 56, 58 control the pressure inside the differential pressure region 62 of the secondary chamber 50, so that the secondary chamber ( 50) forms a dynamic airlock between the melting chamber 30 and the recovery chamber 80.

In various non-limiting embodiments, differential pressure pumps 60 may initially vacuum or substantially vacuum the regions 62, and subsequently the gas bleeds 56 and 58 are equal to the desired melt pressure. Alternatively, gas can be introduced into the region 62 to create substantially the same pressure. For example, the regions 62 may be formed with a substantially vacuum of, for example, about 100 mTorr to about 10 mTorr. Continuously the gas bleeds 56 and 58 may introduce gas to reach a desired melt pressure of, for example, about 400 mTorr to about 1000 mTorr. In various non-limiting embodiments, the pumping system can control the pressure to a desired melt pressure ±25, for example across the secondary chamber 50. If gas is present in the secondary chamber 50, heat transfer from the cast material 26 may be improved and the solidification rate of the cast material 26 may be increased. In other words, the cast material 26 can be cooled and solidified faster when the secondary chamber 50 is filled with an inert gas than when the secondary chamber 50, for example, maintains a vacuum or substantially vacuum. have.

5 and 6, when the cast material 26 is positioned through the region 62 of the secondary chamber 50, the cast material 26, the baffles 64 and the secondary chamber The inner periphery of 50 may, for example, define a boundary of the region 62 in which a desired pressure is formed and/or maintained. Once the boundaries of the region 62 are formed, the differential pressure pump 60, the gas sources 52,54 and/or the gas bleeds 56,58 are inside the region 62 of the secondary chamber 50. Pressure can be adjusted. In various non-limiting embodiments, the differential pressure pumps 60 may control pressures in various regions 62 of the secondary chamber 50 to different pressures. For example, in some non-limiting embodiments, the pressure in the first differential pressure region 62a of the secondary chamber 50 may be increased to a pressure at least slightly higher than the desired melting pressure. For example, the first differential pressure region 62a may be controlled to be about 880 Torr to about 930 Torr when the desired melting pressure is about 825 Torr to about 875 Torr. In other words, the pressure difference between the first differential pressure region 62a and the melting chamber 30 may be, for example, about 10 Torr to about 50 Torr. Also in some non-limiting embodiments, the second differential pressure region 62b can be controlled to be slightly less than the pressure inside the first differential pressure region 62a. For example, the pressure in the second differential pressure region 62b may be controlled from about 825 Torr to about 850 Torr. In various non-limiting embodiments, a pressure difference between the first differential pressure region 62a and the second differential pressure region 62b may be about 10 Torr to about 50 Torr. Accordingly, in some embodiments, the first differential pressure region 62a separates the melting chamber 30 from the continuous regions 62b and 62c inside the secondary chamber 50 and provides a non-inert gas in the external atmosphere. It may be a high-pressure region that prevents from penetrating into the melting chamber 30.

Still referring to Figs. 5 and 6, the pressure in the continuous regions 62c of the secondary chamber 50 between the second differential pressure region 62b and the intermediate differential pressure region 62d is gradually reduced, for example. Can be. In various non-limiting embodiments, the pressure may be gradually reduced by, for example, between about 10 Torr and about 100 Torr between adjacent regions 62. Between the second differential pressure region 62b and the intermediate differential pressure region 62d, the size and number of the pressure regulating element 64 and the region 62 may vary. In at least one embodiment, the number of additional regions 62 depends on the material properties of the molten material 24 and the cast material 26 and the pressure inside the melting chamber 30 and recovery chamber 80. can do. In various non-limiting embodiments, the number of additional regions 62 may depend on the rate of heat transfer from the cast material 26. For example, at least one region 62 may be arranged between the second differential pressure region 62b and the intermediate differential pressure region 62d. In some non-limiting embodiments two to five regions 62 may be arranged between the second differential pressure region 62b and the intermediate differential pressure region 62d. In various non-limiting embodiments, more than five regions 62 may be arranged between, for example, the second differential pressure region 62b and the intermediate differential pressure region 62d. A sufficient number of regions 62 can be arranged between the melting chamber 30 and the intermediate differential pressure region 62d of the secondary chamber 50, so that the cast material 26 is reduced to the intermediate differential pressure region 62d. ) Is sufficiently cooled. The cast material 26 can be cooled to such an extent that exposure to the external atmosphere inside the recovery chamber does not cause contamination. For example, when the cast titanium 26 reaches the intermediate differential pressure region 62d, the cast titanium alloy is cooled to about <1000 to 1200° F. to the lower regions 62e, 62f of the secondary chamber 50. , 62g) and the reaction and contamination of the cast titanium 26 by inert gas in the outside atmosphere can be avoided.

Still referring mainly to FIGS. 5 and 6, the pressure of the intermediate differential pressure region 62d may be controlled to be smaller than that of the adjacent regions of the secondary chamber 50. For example, pressures of regions immediately below and above the intermediate differential pressure region 62d may be greater than the pressure of the intermediate differential pressure region 62d. In other words, the intermediate differential pressure region 62d may be a low pressure region between the first differential pressure region 62a and the final differential pressure region 62g. In some non-limiting embodiments, the pressure in the intermediate differential pressure region 62d may be, for example, from about 250 Torr to about 300 Torr. In various non-limiting embodiments, the pressure in the intermediate differential pressure region 62d may be, for example, from about 100 Torr to about 400 Torr.

Still referring to the embodiment shown in FIGS. 5 and 6, the pressure of the continuous regions 62e and 62f of the secondary chamber 50 between the intermediate differential pressure region 62d and the final differential pressure region 62g. Can be incrementally increased. In various non-limiting embodiments, the pressure may be gradually increased, for example, between about 10 Torr and about 100 Torr between adjacent regions 62. Between the intermediate differential pressure region 62d and the final differential pressure region 62g, the size and number of the pressure regulating elements 64 and the regions 62 may vary. In at least one embodiment the number of regions 62 will depend on the material properties of the molten material 24 and the cast material 26 and the pressure inside the melting chamber 30 and recovery chamber 80. I can. In various non-limiting embodiments, the number of additional regions 62 may be sufficient to gradually increase the pressure in the final differential pressure region 62g to be slightly higher than atmospheric pressure. For example, at least one region 62 may be arranged between the intermediate differential pressure region 62d and the final differential pressure region 62g. In some non-limiting embodiments two to five regions 62 may be arranged between the intermediate differential pressure region 62d and the final differential pressure region 62g. In various non-limiting embodiments, more than five regions 62 may be arranged between the intermediate differential pressure region 62d and the final differential pressure region.

The final differential pressure region 62g may be located adjacent to and/or above the recovery chamber 80. In various non-limiting embodiments, the final differential pressure region 62g may have a pressure at least slightly higher than atmospheric pressure. For example, in certain non-limiting embodiments, the pressure in the final differential pressure region 62g may be, for example, from about 740 Torr to about 850 Torr and/or the pressure in the final differential pressure region 62g. The difference between the atmospheric pressure and the atmospheric pressure may be about 10 Torr to 100 Torr. In other words, the final differential pressure region 62g may be the second high pressure region in the secondary chamber 50.

As described herein, the molten seal 28 provides a seal between the melting chamber 30 and the recovery chamber 80. However, if the molten seal 28 is destroyed, the dynamic airlock of the secondary chamber 50 can provide a second seal so that contamination of the melting chamber 30 is prevented. In addition, the secondary chamber 50 can prevent contamination of the cast material 26 inside the secondary chamber 50 at a temperature at which the cast material 26 is still reactive with an inert gas. Since gas is directed away from the first differential pressure region 62a, that is, a relatively high pressure region, toward the intermediate differential pressure region 62d, that is, a relatively low pressure region, the first differential pressure region 62a prevents contamination. Can be prevented. In other words, the gas is directed away from the melting chamber 30 and toward the intermediate differential pressure region 62d of the secondary chamber 50. In addition, when the molten seal 28 is destroyed, the pressure in the melting chamber 30 does not try to escape from the melting chamber 30 toward the secondary chamber 50, so that the first differential pressure region 62a ) May reduce the pressure change in the melting chamber 30. Conversely, for example, when the molten seal 28 is destroyed, the melting chamber 30 is operated at a positive pressure, and the first differential pressure region 62a is operated at a vacuum or a relatively low positive pressure, the gas is transferred to the secondary chamber. Attempting to leave the melting chamber 30 toward 50 will create a pressure change in the melting chamber 30.

In addition, the non-inert gas outside the secondary chamber 50 and/or the non-inert gas inside the recovery chamber 80 is away from the final differential pressure region 62g, that is, the high pressure region, and the external atmosphere, that is, a relatively low pressure region. Since it faces the final differential pressure region 62g, contamination of the melting chamber 30 may be prevented. In other words, since the final differential pressure region 62g is a high pressure region, the non-inert gas in the external atmosphere will not try to flow from the external atmosphere into the final differential pressure region 62g of the secondary chamber 50. Further, the pressure decreasing from the final differential pressure region 62g to the intermediate differential pressure region 62d will direct the gas flow to the intermediate differential pressure region 62d instead of the final differential pressure region 62d.

Referring again to FIG. 6, the first gas source 52 may hold, for example, a first gas or a combination of first gases, and the second gas source 54 is, for example, a second gas or It can hold a combination of the second gas. Further, in various non-limiting embodiments, at least the first gas or the combination of the first gas may be, for example, an inert gas such as helium and/or argon, or a combination of an inert gas. The first gas supply source 52 transfers gas from the first differential pressure region 62a or the first high pressure region to the region 62 inside the secondary chamber 50 through the intermediate differential pressure region 62d or the low pressure region. Can supply. In other words, the first gas supply source 52 is a pressure region 62 that gradually decreases from the first high pressure region 62a adjacent to the melting chamber 30 through the low pressure region or the intermediate differential pressure region 62d. Can be connected with. Since an inert gas exists in the region 62 adjacent to the melting chamber 30, when the molten seal 28 is destroyed, an inert gas instead of the non-inert gas flows into the melting chamber 30 to melt the melt. It can be ensured that contamination of the molten material 24 inside the chamber 30 can be virtually prevented. The differential pressure pump 60 and gas bleed 56 can withdraw and/or introduce an inert gas from the region 62 to regulate the pressure therein. As described herein, before the cast material 26 leaves the intermediate differential pressure region 62d, the cast material 26 can be sufficiently cooled so that the cast material does not react with the inert gas. Does not. However, the cast material 26 can be sufficiently high temperature and reactive between the first differential pressure region 62a and the intermediate differential pressure region 62d. Thus, for example, the first gas source 52, which supplies gas to the differential pressure regions 62a, 62b, 62c, 62d, prevents contamination of the casting material 26, which is elongated and potentially reactive. In order to do this, an inert gas must be supplied.

Still referring mainly to FIG. 6, the second gas supply source 54 is located after the intermediate differential pressure region 62d and the secondary chamber 50 positioned through the final differential pressure region 62g or the second high pressure region. Gas may be supplied to the inner regions 62. For example, a non-inert gas such as compressed air can be provided by the second gas source 54 without the risk of contaminating the casting material 26 located therein. For example, when the cast material moves out of the intermediate differential pressure region 62d, the cast material 26 can be sufficiently cooled so that the cast material cannot react with inert gas. In alternative embodiments, the second gas source 54 may comprise or consist essentially of an inert gas.

In various non-limiting embodiments, the differential pressure pumps 60 may be connected with a gas recovery system (not shown in the drawings). The inert gas used in the continuous casting system 20 is expensive, and the gas recovery system attempts to recover and recycle the inert gas for future use. For example, the gas recovery system can pump gas from the regions 62 of the secondary chamber 50, compress the extracted gas, pass the gas through a purification system, and pass the gas through the gas supply sources 52,54. Can be returned to. In other words, the gas can be recycled through the system. In various non-limiting embodiments, the purification system of the gas recovery system may be located outside the melting furnace 22. For example, an inert gas is supplied to the upper regions 62a, 62b, 62c, 62d of the secondary chamber 50 by the first gas supply source 52, and for example, a non-inert gas is supplied to the second gas supply source. In some embodiments fed to the lower regions 62e, 62f, 62g of the secondary chamber 50 by 54, the gradual decrease from the first differential pressure region 62a to the intermediate differential pressure region 62d The pressure to be applied may, for example, allow recovery of the inert gas used in the regions 62a, 62b, 62c, 62d. In at least one embodiment, a small volume of non-inert gas may flow from the adjacent low pressure region 62e to the intermediate differential pressure region 62d controlled to a relatively low pressure during a continuous casting operation. In various non-limiting embodiments, the gas flow volume between adjacent regions 62 can be minimized. For example, the gas flow volume may depend on the space between the cast material 26 and the pressure regulating element 64 and the pressure difference between adjacent regions 62. In various non-limiting embodiments, an intermediate differential pressure pump 64d corresponding to the intermediate differential pressure region 62d draws gas from the intermediate differential pressure region 62d. Before the gas returns to the first gas source 52, for example, a small volume of non-inert gas drawn out by the pump 64d can be removed, so that the inert gas is passed through the continuous casting system 20. The materials 24 and 26 may be recycled within the reacting chambers and/or regions. Conversely, if the pressure inside the secondary chamber 50 increases to atmospheric pressure after the first differential pressure region 62a instead of gradually decreasing to the low pressure region 62d, the inert gas in the first differential pressure region 62a Can escape to the outside atmosphere, for example.

In various non-limiting embodiments mainly referring to FIGS. 6 and 7, the recovery chamber 80 may be located adjacent to the secondary chamber 50. In some embodiments, the recovery chamber 80 may be arranged movably relative to the secondary chamber 50. When the recovery chamber 80 is positioned close to the secondary chamber 50, the secondary chamber 50 and the recovery chamber 80 may be sealed to each other. For example, an O-ring or gasket 70 (FIG. 6) may be arranged between the recovery chamber 80 and the secondary chamber 50 to provide a vacuum seal therebetween. Additionally or alternatively, a hydraulically driven lock (not shown in the figure) can seal the recovery chamber 80 to the secondary chamber 50, for example. In various non-limiting embodiments, the recovery chamber 80 may be controlled to the same pressure as the melting chamber 30, that is, a desired melting pressure. As described herein, the recovery chamber 80 has an atmospheric pressure during the continuous casting process and is operable, and the secondary chamber 50 is between the melting chamber 30 and the recovery chamber 80 that can be maintained at a desired melting pressure. Dynamic airlock can be provided.

When mainly referring to FIG. 1, the restraint release or recovery cart 100 may be located adjacent to and/or below the recovery chamber 80. The recovery cart may include, for example, a platform 102 capable of supporting the recovery chamber 80. In some embodiments, operation of the recovery cart 100 may raise and/or lower the recovery chamber 80. For example, the recovery cart 100 may include a second recovery ram 104 capable of moving and operating the recovery platform 102 upward and downward relative to the secondary chamber 50. In various non-limiting embodiments, the recovery ram 104 may pull the recovery platform 102 downward to release the recovery chamber 80 from the secondary chamber 50. The release of the restraint of the recovery chamber 80 may open the recovery chamber 80 to an external atmosphere. In other words, when the recovery chamber 80 is separated from or moved away from the secondary chamber 50, the seal between the recovery chamber 80 and the secondary chamber 50 may be destroyed. However, even when the recovery chamber 80 is opened to the external atmosphere and has atmospheric pressure, the molten material 24 inside the melting chamber 30 is a dynamic airlock of the secondary chamber 50 and molten With respect to the seal 28, it can be kept protected from inert gases in the atmosphere. 1 and 8, the recovery cart 100 may be arranged on a guide track or rail 106. The recovery cart 100 may, for example, comprise wheels and may roll along the track or tracks 106 between an operating position (FIG. 1) and a staging position (FIG. 8 ). . In various non-limiting embodiments, when the second recovery ram 104 is folded to remove the platform 102 and the recovery chamber 80 is lowered, the recovery cart 100 can move to the staging position. have.

Referring again to FIG. 7, the continuous casting system 20 may include a first set of rollers 92. In various non-limiting embodiments, the first set of rollers 92 may be configured to move between a retracted position (FIG. 5) and an extended position (FIG. 7 ). For example, the first set of rollers 92 may extend towards the cast material 26 so that the first set of rollers 92 can be used when the first set of rollers is in an extended position. Can come into contact with the cast material 26. In various non-limiting embodiments, the first set of rollers 92 are in contact with the cast material 26 after the recovery chamber 80 is contracted and/or released from the secondary chamber 50. can do. For example, the first set of rollers 92 may be obstructed by the recovery chamber 80, so that the first set of rollers 92 are molded before the recovery chamber 80 is retracted. It is prevented from extending to the material 26. In some non-limiting embodiments, the first set of rollers 92 may help control the rate of recovery of the cast material 26. In other words, the rotational speed of the first set of rollers 92 may affect the speed at which the cast material 26 leaves the mold 36.

Referring to FIG. 8, the continuous casting system 20 may include a second set of rollers 94. In various non-limiting embodiments, the second set of rollers 94 may be configured to move between a retracted position (FIG. 5) and an extended position (FIG. 8 ). For example, the second set of rollers 94 may extend towards the cast material 26 so that the second set of rollers 94 when the second rollers 94 are in the extended position. Among them, the rollers are in contact with the cast material 26. In various non-limiting embodiments, the second set of rollers 94 are in contact with the cast material 26 after the recovery chamber 80 is retracted and/or released from the secondary chamber 50. can do. For example, the second set of rollers 94 are obstructed by the recovery chamber 80 so that the second set of rollers 94 can be used to form the cast material 26 before the recovery chamber 80 is retracted. Is prevented from extending to. In some embodiments, the second set of rollers 94 may help control the rate of recovery of the cast material 26. In other words, in some embodiments the rate of rotation of the second set of rollers 94 may affect the rate at which the cast material 26 leaves the secondary chamber 50. In addition, the second set of rollers 94 can direct the cast material 26 to the unloading device, as described herein. In various non-limiting embodiments as yet mainly referring to FIG. 8, after the cast material 26 is withdrawn through the secondary chamber 50, the cutting device 96 removes the cast material 26. Can be cut. The cutting device 96 is capable of cutting the cast material 26, for example, below the first set of rollers 92 and/or above the second set of rollers 94, for example. .

Referring now to FIGS. 8 and 9, in certain non-limiting embodiments the first unloading device 110 may include a telescoping support mechanism 112 and/or a gripper 114. have. The grippers 114 may, for example, hold or capture the cast material 26 under the first and/or second set of rollers 92,94. In addition, in various non-limiting embodiments, the telescoping support mechanism 112 may fix the grippers 114. In at least one embodiment, the telescoping support mechanism 112 may be folded or partially folded to lower the cast material 26 secured by the grippers 114. The telescoping support mechanism 112 can be folded, for example, to move the cast material 26 from a vertical structure (FIG. 8) to a horizontal structure (FIG. 9 ). Referring primarily to FIG. 9, for example, the first unloading device 110 is arranged along the guide tracks 106 to move the cut segment of the cast material 26 away from the continuous casting system 20. You can move or cloud movement.

Referring to FIG. 10, in various non-limiting embodiments, the continuous casting system 20 may include a second unloading device 118. In various non-limiting embodiments, the second unloading device 118 may include a support member 120 securing the additional rollers 122. In some embodiments, additional rollers 122 may steer the cast material 26 along a path formed by the support member 120 and/or additional rollers 122. The rollers 122 may steer the cast material 26 along a contoured path, for example, and steer the cast material 26 from a vertical structure to a horizontal structure, for example. . In various non-limiting embodiments, the cutting device 96 can cut a segment of the cast material 26 after the support member 120 guides the cast material 26 to the desired structure. have.

Referring primarily to FIGS. 1-11, the operation of the continuous casting system 20 may include an initialization step 202 and a continuous casting step 204. In various non-limiting embodiments, the recovery chamber 80 may be sealed to the secondary chamber 50 during an initialization step 202 of the casting operation. In some non-limiting embodiments, the continuous casting step 204 of the casting operation may begin when the recovery chamber 80 is released from the secondary chamber 50. In step 210 of the initialization step 202, the pumping system may form the melting chamber 30, the secondary chamber 50, and the recovery chamber 80 in a vacuum or substantially vacuum state. For example, in certain non-limiting embodiments, the pressure of the melting chamber 30, the secondary chamber 50, and the recovery chamber 80 may be formed from about 100 mTorr to about 100 mTorr. In various non-limiting embodiments, the melting chamber 30, the secondary chamber 50, and the recovery chamber 80 may have a low leakage rate. For example, in various non-limiting embodiments, the melting chamber 30, the secondary chamber 50, and the recovery chamber 80 may have a leak rate of less than about 10 mTorr per minute to about 5 mTorr per minute. The integrity of the melting chamber 30, the secondary chamber 50, and the recovery chamber 80 may be confirmed. In step 212, the pumping system may control the pressure inside the melting chamber 30, the secondary chamber 50, and the recovery chamber 80 to a desired melting pressure. For example, when the desired melting pressure is a positive pressure, the melting chamber 30, the secondary chamber 50, and the recovery chamber 80 may be backfilled with an inert gas to reach the desired melting pressure.

In various non-limiting embodiments, step 214 may be initiated once a desired melt pressure has been obtained across the melting chamber 30, the secondary chamber 50 and the recovery chamber 80. In step 214, energy may be applied to the material 24 inside the melting chamber 30 to melt the material 24. Subsequently at step 216, the molten material 24 may pass from the melting chamber 30 through the secondary chamber 50 and into the recovery chamber 80. For example, material may enter the mold 36 as molten material 24 and leave the mold 36 as cast material 26. The cast material 26 is then moved into the recovery chamber 80 through the secondary chamber 50, for example.

Further, in step 218 of the initialization step 202, the pressure in the first differential pressure region 62a may be controlled to a first differential pressure that is at least slightly greater than the desired melting pressure. Further, in step 220, the pressure in the second differential pressure region 62b may be controlled to a second differential pressure that is at least slightly smaller than the first differential pressure. In other words, the first differential pressure region 62a separates the melting chamber 30 from the continuous region 62 of the secondary chamber 50 and pollutes the melting chamber 30 by non-inert gas in the external atmosphere. It may be a high-pressure area to prevent.

Further, the pressure in the continuous region(s) 62 in step 222 of the initialization step 202 is, for example, progressively between the second differential pressure region 62b and the intermediate differential pressure region 62d. Can be reduced to Further, in step 224, the intermediate differential pressure region 62d may be controlled to, for example, the lowest pressure in the region 62 of the secondary chamber 50, the intermediate differential pressure region. In other words, the intermediate differential pressure region 62d may be a low pressure region between the first differential pressure region 62a and the final differential pressure region 62g. Further, in step 226, the pressure of the successive regions between the intermediate differential pressure region 62d and the final differential pressure region 62g may be gradually increased to atmospheric pressure, for example. Further, in step 228, the pressure in the final differential pressure region 62g may be controlled to a pressure at least slightly greater than atmospheric pressure, for example.

When the cast material 26 is positioned via the pressure adjustment elements 64 forming the sides of the region 62, the adjacent regions 62 can hold or substantially hold different pressures. Thus, in various non-limiting embodiments, the pressure in each region can be controlled at any time after the cast material 26 has been extended through each region 62. In various non-limiting embodiments, after the cast material 26 moves through the entire secondary chamber 50 and enters the recovery chamber 80, the region 62 of the secondary chamber 50 The pressures of the fields can be controlled at the same time to different operating pressures, i. In other words, steps 218, 220, 222, 224, 226 and 228 may be initiated simultaneously. For example, once cast material 26 enters recovery chamber 80, the pumping system may be operated to initiate steps 218, 220, 222, 224, 226 and 228. Additionally or alternatively, the pressure in the region 62 can be continuously controlled as the cast material 26 advances through the secondary chamber 50. For example, step 218 is followed by step 220, followed by step 222, then step 224, then step 226, and then Step 228 may proceed. In various non-limiting embodiments, the pressure in each region 62 may be adjusted after the cast material has passed through the region 62. In other embodiments, the steps may be performed in a different order.

Also during the initialization step 202 in step 230, the recovery chamber 80 may be controlled to atmospheric pressure. In various non-limiting embodiments, the recovery chamber 80 may be released from the secondary chamber 50 to have atmospheric pressure. In other words, the release of the restraint of the recovery chamber 80 may destroy the seal between the secondary chamber 50 and the recovery chamber 80. Further, when the recovery chamber 80 is released from the secondary chamber 50, the continuous casting system 20 can operate so that the cast material 26 can continue to extend from the mold 36. have. In various non-limiting embodiments, the recovery chamber 80 is unconstrained from the secondary chamber 50 to provide space for the extended length of the cast material 26.

During the subsequent casting step 204 of the casting operation, the molten material 24 may continue to move from the recovery chamber 80 through the secondary chamber 50, ie step 232. In various non-limiting embodiments, the recovery chamber 80 may remain unconstrained and/or removed from the secondary chamber 50. Therefore, the cast material 26, from the melting chamber 30 maintained at a desired melting pressure, through the secondary chamber 50 controlled at various different pressures, into the external atmosphere, will continue to flow. I can. The dynamic airlock of the secondary chamber 50 and the molten seal 28 are contaminated by the external atmosphere within the recovery chamber 80 and/or outside the secondary chamber 50. Can be prevented. Also in various non-limiting embodiments, for example in step 234, the cast material may be rolled between a set of first and/or second rollers 92,94; In step 236, the cast material 26 can be cut by means of a cutting device 96; And/or, in step 238, the cast material 26 may be unloaded by one of the unloading devices 110,118. For example, before and/or after the cast material 26 is cut by the cutting device 96, the cast material 26 may be formed between a set of first and/or second rollers 92,94. Can be rolled in. Also, for example, the cast material 26 may be cut by the cutting device 96 before and/or after the cast material 26 is unloaded by one of the unloading devices 110,118. have. The continuous casting step 204 of the continuous casting operation may continue until no additional material 24 is supplied into the mold 36.

While various embodiments of the equipment, systems, and methods described herein are described in connection with the casting of reactive metals and metal alloys, the present invention is not so limited, and the present invention is not so limited and all that have or do not have reactivity in the molten state or at high temperatures It will be appreciated that it may be used in connection with the casting of metals or metal alloys.

Various embodiments have been described and illustrated herein in order to fully understand the use, steps and elements of the described apparatus and methods. It is understood that the various embodiments described and illustrated herein are non-limiting and non-exhaustive. Therefore, the present invention is not limited by the description of various embodiments disclosed herein, non-limiting and non-exhaustive. Features and characteristics described in connection with various embodiments in an appropriate environment may be combined, modified or reconfigured with steps, portions, elements, features, characteristics, aspects, limitations, and the like of other embodiments. The above modifications and changes should be included within the scope of this specification. Accordingly, the claims may be amended to refer to all elements, steps, limitations, features and/or features that are expressly or essentially described herein or otherwise expressly or essentially supported by this specification. . In addition, Applicant reserves the right to amend the claims to affirmatively abandon elements, steps, limitations, features and/or features present in the prior art, irrespective of whether the above features are explicitly described. Therefore, all the above amendments meet the requirements of 35 U.S.C.§ 112, paragraph 1 and 35 U.S.C.§ 132(a). The various embodiments disclosed and described herein may include, constitute, or consist essentially of the steps, limitations, features, and/or features variously described herein.

All patents, publications, or other publicly available materials identified herein are incorporated herein by reference in their entirety, unless stated otherwise, but the material contained therein conflicts with existing definitions, statements, or other publicly available materials expressly disclosed herein. It is included to the extent that it does not cause. Accordingly, and to the extent necessary, the express disclosures disclosed herein supersede any conflicting material incorporated herein by reference. Any material or portion of material that is described as being incorporated herein by reference but conflicts with existing definitions, statements, or other publicly available material disclosed herein, to the extent that there is no conflict between the material contained and existing publicly available material. Only included. Applicant reserves the right to amend the above specification to explicitly refer to any subject matter or portions thereof incorporated herein by reference.

The grammatical articles "a", "any", "any" and "a", as used herein and when used, are "at least one" or "one or more" unless otherwise stated. Must include. Thus, the articles are used herein to refer to one or more (ie, “at least one”) of the grammatical objects of the article. For example, "a part" means more than one part, and thus, possibly, more than one part is contemplated and may be used or used in the practice of the described embodiments. In addition, the use of singular nouns includes plural nouns, and the use of plural nouns includes singular nouns unless the phraseology context requires otherwise.

20....continuous casting system,
22....no,
30....melting chamber,
50....secondary chamber,
80....recovery chamber.

Claims (23)

As a method for casting a material,
Including the step of controlling the pressure inside the melting chamber, the secondary chamber, and the recovery chamber to the melting pressure,
Passing a material cast from the molten material in the melting chamber into the secondary chamber, wherein the secondary chamber includes a plurality of regions, and the plurality of regions define a first region adjacent to the melting chamber. Includes,
Passing the cast material from the secondary chamber into a recovery chamber,
Controlling the pressure in the first region from the melting pressure to a first differential pressure greater than the melting pressure,
Controlling the pressure in the second region to a second differential pressure smaller than the first differential pressure,
And controlling the pressure in the recovery chamber from the melt pressure to atmospheric pressure. The method of claim 1, comprising vacuuming the melting chamber, the secondary chamber, and the recovery chamber before controlling the pressure inside the melting chamber, the secondary chamber, and the recovery chamber to the melting pressure. . The method of claim 2, further comprising filling the melting chamber, the secondary chamber, and the recovery chamber with an inert gas after vacuuming the melting chamber, the secondary chamber, and the recovery chamber. The method of claim 1, wherein the plurality of regions of the secondary chamber further includes a final region operably located adjacent to the recovery chamber, and the method comprises controlling the pressure of the final region to a final differential pressure greater than atmospheric pressure. Method characterized in that it further comprises a. The method of claim 4, wherein the plurality of regions of the secondary chamber comprises an intermediate region, and the method further comprises controlling pressures in regions located between the second region and the intermediate region among the plurality of regions. Wherein the pressures are adjusted from the melt pressure to a continuously decreasing pressure from the second region to the intermediate region. 6. The method of claim 5, wherein the pressure of the regions located between the second region and the intermediate region is continuously reduced from 10 Torr to 100 Torr between adjacent regions. The method of claim 4, wherein the plurality of regions of the secondary chamber comprises an intermediate region, and the method further comprises controlling a pressure in the plurality of regions located between the intermediate region and the final region, the pressures A method, characterized in that it is adjusted from the melt pressure to a continuously increasing pressure from the intermediate region to the final region. The method of claim 1, further comprising melting the material by supplying energy to the material inside the melting chamber. The method of claim 1, further comprising moving the recovery mechanism to move the cast material through the secondary chamber and into the recovery chamber. The method of claim 1, further comprising deconstraining the recovery chamber from the secondary chamber to control the pressure in the recovery chamber from melt pressure to atmospheric pressure. The method of claim 1, further comprising extending the set of rollers to contact the cast material. The method of claim 1, further comprising cutting the cast material with a cutting device. 13. The method of claim 12, further comprising the step of lowering the cut segment of the cast material onto the cart. The method of claim 1 wherein the melt pressure is greater than atmospheric pressure. The method of claim 1, wherein the pressure in each of the plurality of regions of the secondary chamber is individually controlled. 16. The method of claim 15, wherein the pressure in the plurality of regions of the secondary chamber is controlled by a plurality of pumps. The method of claim 16, further comprising recovering and recycling the gas supplied by the plurality of pumps. 18. The method of claim 17, wherein the gas comprises an inert gas. 18. The method of claim 17, wherein the recovered gas is compressed and purified prior to returning to the gas source. As a method for casting a material,
Controlling the pressure inside the melting chamber, the secondary chamber, and the recovery chamber to a melting pressure;
Passing a cast material made from the material inside the melting chamber into the secondary chamber, the secondary chamber including a plurality of areas, and the plurality of areas including a first area adjacent to the melting chamber And
Passing the cast material from the secondary chamber into a recovery chamber,
Controlling a pressure in the first region from a melting pressure to a first differential pressure greater than the melting pressure to form a dynamic airlock and protect the melting chamber from atmospheric inert gas,
Controlling the pressure of the final region to a final differential pressure greater than atmospheric pressure, and the pressure of the regions of the secondary chamber is adjusted to continuously decrease from the first region to the intermediate region,
And controlling the pressure in the recovery chamber from the melt pressure to atmospheric pressure. 21. The method of claim 20, further comprising reducing the pressure within the intermediate region to direct gas towards the intermediate region. 21. The method of claim 20, wherein the pressure in the plurality of regions of the secondary chamber is controlled by a plurality of pumps. In the chamber for a continuous casting furnace,
Including the inner perimeter,
Includes a plurality of areas, the plurality of areas
A first region located adjacent to the melting chamber of the furnace, the melting chamber configured to operably reach a melting pressure, the first region operatively reaching a first differential pressure greater than the melting pressure Composed,
Comprising a second region located adjacent to the first region, the second region operatively configured to reach a second differential pressure less than the first differential pressure,
Comprising at least one baffle for controlling gas flow between adjacent regions of a plurality of regions, each baffle including a hole, each baffle extending from the inner circumference of the chamber to the hole Chamber.

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